Method for fabricating an air gap pipe

A method for forming a non-linear air gap pipe for use with an engine exhaust system, said air gap pipe comprising inner and outer pipes dimensioned to enable the inner pipe to be supported within the outer pipe with an air gap therebetween, said method comprising the steps of:

• forming inwardly extending resilient dimples in the outer pipe extending inwardly a distance sufficient to support the inner pipe therein;
• bending the inner and outer pipes into substantially identical non-linear configurations for use in the exhaust system;
• providing a cutting apparatus selected from the group consisting of laser cutting apparatus and plasma arc cutting apparatus, said cutting apparatus being movable and programmable to follow the nonlinear configuration of the bent outer pipe;
• securely mounting the bent outer pipe in proximity to the cutting apparatus;
• moving the cutting apparatus relative to the outer pipe to cut the outer pipe longitudinally in half to define first and second outer pipe halves;
• supporting the inner pipe on the dimples of the outer pipe and intermediate the first and second outer pipe halves;
• and
• welding the outer pipes halves together at selected locations to define an air gap pipe and to control the flow of heat from the air gap pipe.